‘SMOOTHFLOWSASHDRIVE’

Fume Cupboardand Fumeflow FanUSER MANUAL

CONTENTS:

FEATURES1. Smoothflow Fume Cupboard Features2. Sash Stop3. Baffles

PREPARATION4. Warning!5. Guidelines for Safety

OPERATION6. Operating Instructions7. Faults8. Trouble shooting

MAINTENANCE9. Monthly10. Six Monthly11. Annually

EXAMPLE AUDIT REPORT

Calibre Solutions Ltd37 Manurere Rise, RD1 Matakohe 0593

Freephone: 0800 422 542Phone: +64 21 684 273

Fax: +64 9 813 1319

Smoothflow Fume Cupboard Features

Microprocessor controllercontrols all aspects of operation via the control keypadthe controller is located on top of the fume cupboardRCD* protection device for the power socketsbattery* energy for the mains power failure alarm*refer maintenance instructions

Light illuminates the work areathe light is located on top of the fume cupboard

Sash stoplimits the opening height of the sash in normal operationreleases the sash to full height for service accesslocated on the left front pillar

Smoothflow Fume Cupboard Features (cont.)

Control keypadinput keys to start, stop and activate the fume cupboarddisplays the fume cupboard status and alarms*refer operating instructionslocated on the right above the sash opening

Power outletdouble socket for electrical appliancesavailability of power strictly controlled*refer operating instructionslocated on the right front pillar

Label important user informationspillage capacitywarning noticefume cupboard serial numberlocated on the right corner of the sash

Water valvecontrols water flow to water spout inside the fume cupboardlocated under the sill

Gas valvecontrols gas flow to gas spout inside the fume cupboardflammable gases have push-turn mechanismavailability of flammable gases strictly controlled*refer operating instructionslocated under the sill

SASH STOP

The sash stop is located on the left front pillarThe sash stop limits the sash opening height to about 480mm. With the opening restricted, less air flow is required to achieve fumecapture. The sash can be released for maximum opening for cleaning inside the fumecupboard, or setting up equipment before the work starts.

ALWAYS lower the sash before commencing work

NEVER use the fume cupboard with the sash above the stop.

To release the sash:

Raise the sash until it reaches the upper stop position1. Insert a coin or key in the slot of the sash stop2. Twist the sash stop clockwise about a quarter turn and hold3. Raise the sash above the stopRelease the stop and withdraw the coin or key.The stop will automatically reset when the sash is lowered

ALWAYS lower the sash before commencing work.

NEVER use the fume cupboard with the sash above the stop.

BAFFLES

There are two baffles in the fume cupboard. The baffles are easily removed tofacilitate cleaning of the entire fume chamber. This should be done as often as thework requires, and at least monthly (refer maintenance instructions)

ALWAYS remove ALL chemicals and equipment from the fume cupboard.

ALWAYS wear personal protective equipment before handling baffles. Protectiveequipment must be suitable for the chemicals used inside the fume cupboard. Referto Supervisor. Minimum requirements are overalls or coat with long sleeves;suitable eye protection - glasses, goggles or mask; and suitable gloves.

Rear BafflesThe rear baffles are sprung between a row of hooks inside the back of the fumecupboard, and a corresponding row of hooks under the roof (see drawing). Thebaffle is in two pieces, with a vertical join in the centre. The join cover strip isattached to the RIGHT hand baffle. Remove this baffle first.

1. To remove the baffle, place both (gloved) hands, palms up, under thebottom edge of the baffle. Raise the baffle and bring it forward, over thehooks.

2. Bring the bottom edge of the baffle forward over the sill, 3. Disengage the top edge of the baffle from the upper hooks. 4. Repeat the action with the left baffle.

Replace the baffles by reverse action.5. Replace the left baffle (without cover strip) first. Hold the baffle with the

edge notch at the top left corner, and the slots offset towards the centre ofthe fume cupboard (see diagram).

6. Lift the baffle into the fume cupboard and engage the top edge of the bafflein the upper hooks.

7. Lift the bottom edge of the baffle over the sill, 8. Carry the baffle to the back of the fume cupboard, and lift the bottom edge

onto the rear hooks. 9. Check alignment in top and bottom hooks.10. Hold the right baffle with the edge notch at the top right corner, and the

cover strip towards the centre of the fume cupboard. 11. Repeat actions 6 - 9 above with the right baffle.

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The label located at the bottom right corner of the sash has important userinformation.

1. The spill containment volume of this fume cupboard is stated on the label.The Supervisor may use this volume to limit quantities of chemicalspermitted in the fume cupboard.

2. BEFORE the fume cupboard is used, the Supervisor is responsible forcarrying out a RISK ANALYSIS of the work. Consider the nature ofchemicals and processes to be used, to determine limiting quantities ofhazardous, flammable, oxidizing and corrosive substances allowed withinthe fume cupboard. Remember that all liquids within the fume cupboard(including water) may displace other substances during an incident. Thesupervisor is to make a list of chemical quantity limits, which is to be readilyaccessible to all persons using the fume cupboard.

3. Ignition sources are not to be placed within the sump of the fume cupboard.

4. In the event of a spill or fire, ISOLATE the fume cupboard. Press the (red)“fume cupboard emergency isolator” button on the keypad. This willimmediately shut off the power and flammable gas outlets. The fan willkeep going. Refer operating instructions.

5. The serial number of this fume cupboard may be requested when seekingtechnical support, available Toll Free in New Zealand: 0800 422 542

WARNINGSpillage volume XX L

Observe chemical limitsspecified by Supervisor

No ignition sources in sumpISOLATE FUME CUPBOARD

in case of spills or fire

SmoothflowFume Cupboard Serial No. XXX

Calibre Plastics LtdAuckland

GUIDELINES FOR USING FUME CUPBOARDS

The fume cupboard is a ventilated work space designed aerodynamically for thesafety of the operator. It will not work properly if it is cluttered up with excessequipment or vessels, which affect the air flow.

Before starting work, clean out the fume cupboard. Remove everything which isnot needed. All chemicals from the fume cupboard should be removed to a suitablestore. Cleaning the internal surfaces will reduce the risk of contamination. It willalso reduce the risk of mixing incompatible substances.

Before starting work, refer to the Laboratory Supervisor’s risk analysis and scheduleof chemical quantities permitted in the fume cupboard. Make sure that the fumecupboard is suitable for the intended use, and has enough space to do the worksafely.

Adopt work methods that minimise the release of fumes. Consider appropriatequantities of substances involved, the rate of reaction, and design of apparatus.

Make sure the fume cupboard is working. Start up the fume cupboard (seeoperating instructions), and check the status of all alarms, especially air flow. Lookaround the room and close any windows or doors which could cause cross-draughts

Set up all the equipment required for the work inside the fume cupboard, withsufficient quantity of reagents. Position apparatus and materials near the centre andrear of the work space. Ignition sources are not to be placed within the sump of thefume cupboard. Check that a suitable fire extinguisher is at hand.

The fume cupboard is now ready for use.Wear protective equipment appropriate to the task.Keep the sash lowered as much as practical during use.

In the event of a spill or fire, ISOLATE the fume cupboard. Press the (red) “fumecupboard emergency isolator” button on the keypad. This will immediately shut offthe power and flammable gas outlets. The fan will keep going. Refer operatinginstructions.

After use, dispose of waste substances with due regard for their potential to createhazards, and within the rules of the local water authority. Refer also to theLaboratory Supervisor, and the laboratory risk analysis.

Maintain the fume chamber in clean condition to avoid chemical contaminationand damage to the fume cupboard. Remove unused chemicals to a suitable store.Do not use a fume cupboard for storage of chemicals. Lower the sash.

OPERATING THE FUME CUPBOARD

Start up Press the green buttonThe fan and light turn onThe TEMPERATURE LED will be greenThe controller waits 7 seconds for airflow

Pre-purge The AIRFLOW LED turns greenThe PRE-PURGE LED will be amber for 50 secondsthen flash for another 10 seconds, then go out

Ready The READY LED turns greenFour beeps sound

Active Press the yellow buttonThe POWER & GAS LED turns greenThe fume cupboard is now operational -power & gas can be used

Isolate / Ready Press the red buttonPower & Gas turn off automaticallyThe POWER & GAS LED goes outThe READY LED turns greenPress the yellow button to re-activate, or

Shut down Press the red button again

Post-purge The fan and light continue to operateThe POST-PURGE LED will be amber for 4 minutesthen flash for another 1 minute, then go out.The light and fan turn off automatically

Re-start Press the green button to return frompost-purge to pre-purge

FUME CUPBOARD

EMERGENCY ISOLATOR

PRE-PURGEPOST-PURGE

AIRFLOW

TEMPERATURE

SCRUBBER

READY

POWER & GAS

SPRAY BAR

RED

GREEN

YELLOW

Sashdrive variable speed fan controlThe fume cupboard sash has an electronic sensor. The fan speed is regulated to suit the sash opening.Lower the sash to save energy loss from the room

FAULT ALARMS

If the Power is cut, an alarm will sound a slow beepThe READY LED will flash redPress the red button to mute the alarmA long beep will sound as the controller shuts down.

When the Power is restored, The fan will automatically turn on for 20 minutes then turn off;An alarm will sound for 30 seconds, then turn offThe LED's will keep flashing.Press the red button to reset the controller and stop the fan.Press the green button for normal start up.

If the Airflow gets low An alarm will sound , and the AIRFLOW LED will flashPress the red button to mute the alarmThe fume cupboard will go into normal post-purge, but the AIRFLOW LED will be redCheck out what caused the alarm. Get it fixed before using the fume cupboard again.

If the Temperature inside the fume cupboard gets highThe TEMPERATURE LED will flash green as a warningTurn down the heat inside the fume cupboard

If the temperature inside the fume cupboard gets higherAn alarm will sound , and the TEMPERATURE LED will flashPress the red button to mute the alarmThe fume cupboard will go into normal post-purge, but the TEMPERATURE LED will be redCheck out what caused the alarm. Get it fixed before using the fume cupboard again.

The temperature sensor works even when the fume cupboard is turned off.Press the red button to mute the alarm

TECHNICAL SUPPORT FREEPHONE 0800-422-542

TROUBLE SHOOTING

No power at power socket

Power is made available to the socket outlet only during “Active” status.Refer operating instructions. After the pre-purge is complete and the ReadyLED lights up green, press the yellow button to activate the power outlet.

If the Power & Gas LED is lit up and there is still no power, check the RCDbreaker (the blue switch visible in the lid of the control box on top of thefume cupboard). When it is on, the switch lever is inclined toward the back of the fumecupboard. If the switch will not latch on, there is an electrical fault in thecircuit. Call an electrician.

No gas at gas outlet

Gas is made available to the outlet only during “Active” status. Referoperating instructions. After the pre-purge is complete and the Ready LEDlights up green, press the yellow button to activate the gas outlet.

If the Power & Gas LED is lit up and there is still no gas, check the RCDbreaker (the blue switch visible in the lid of the control box on top of thefume cupboard). When it is on, the switch lever is inclined toward the back of the fumecupboard. If the switch will not latch on, there is an electrical fault in thecircuit. Call an electrician.

If the power socket is live but there is still no gas, the gas mains may beisolated. Some laboratories have a master gas isolator.

Controller does not respond to keypad

If the control sequence has become corrupted, the controller needs to re-load the program from memory, which happens automatically on powerrestore.

The mains isolator switch is visible in the lid of the control box on top ofthe fume cupboard. The mains isolator is the switch on the left. When it ison, the switch lever is inclined toward the back of the fume cupboard.

Turn off mains supply to the fume cupboard controller. Wait 5 seconds,then turn the mains isolator on again. The processor will reboot, and signala power restore alarm (see operating instructions) Press the red button toreset the controller, and start the fume cupboard as normal.

MAINTENANCEBEFORE undertaking any maintenance of the fume cupboard, obtain asummary of chemical or other hazards from the laboratory supervisor

BEFORE undertaking any maintenance of the duct or fan, isolate the powersupply and tag the fume cupboard “system under maintenance - do not use”

Monthly MaintenanceRemove all chemicals and equipment from the fume chamber. Remove the rear baffles as described in Section 3 of this manualClean the fume chamber with dilute detergentReplace the baffles

Test the RCD (earth leakage) circuit breakerRefer to “Features” Section of this manual for location of the RCD.Press the blue “Test” button. The breaker should immediately trip “off”Reset the breaker to the “on” position.

Six Monthly MaintenanceIn addition to monthly tasks, clean the fluorescent light tube, and the lightpanel in the roof of the fume chamber.

Inspect and maintain fans, motors, drive belts and bearingsCheck all plastic bolts, and replace if UV-brittle.

Perform smoke and velocity tests as AS/NZS 2243.8 Appendices F and ESubmit a maintenance and test report to the laboratory supervisor

Annual MaintenanceIn addition to six monthly tasks, carefully inspect the fume chamber fordefects, and repair as required.Check the sash counterweight cords for wear.Ensure that service controls and outlets are in good condition.Check operation of controller and automatic isolators.

Replace 9V battery for power failure alarmRefer to “Features” Section of this manual for location of the battery.Lift and pull the battery drawer on the front of the control box.Observe polarity carefully when fitting the new battery.Close the battery drawer.

Inspect the exhaust duct from fume chamber to stackAssess the whole system for compliance with AS/NZS 2243.8Perform smoke and velocity tests as AS/NZS 2243.8 Appendices F and ESubmit a maintenance, audit and test report to the laboratory supervisor.Affix a label to the fume cupboard showing date of inspection and overalltest result.

COMMISSIONINGRefer the operating instructions appendedTurn the power on and reset the controller.Manually start the VSD, and check fan rotation.Start the fume cupboard controller.If the airflow alarm goes off, mute the alarm.

Measure the airflowRaise the sash to the maximum operating position (sash stop)Measure the air velocity in the plane of the sash at six (6) positions

The average velocity (sash open) should be more than 0.5m/secLower the sash to the minimum position (sash stop)Measure the air velocity in the plane of the sash at 3 positions

The average velocity (sash closed) should be more than 0.75m/secAdjust fan speed range by program limits on VSD

Record the velocity measurements in a commissioning report.Conduct a smoke test (AS 2243.8) and record the observations.

Adjust the airflow sensor:The airflow sensor is mounted on the roof of the fume chamber at the right endof the light panel, under a loose cover. It measures the velocity of air passinginto the fume chamber through an opening in the sensor circuit board. When the velocity is below the set point, a red LED lights up.

Adjust the velocity set point

There is a 10 turn trimpot on the sensor circuit board beside the cable Adjust the alarm set trimpot - anti-clockwise lowers the setpointTo check the alarm, cover the hole on the sensor with clean dry paper toobstruct airflow. The red LED should light up after a short delay of 5-10 sec

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